Grate system having multiple bearing bars

ABSTRACT

A larger clear span grating system incorporating pairs of bearing bars spaced apart from other pairs of bearing bars by intervening swaged bars. The pairs of bearing bars are spaced apart but immediately adjacent each other relative to the swaged bars. The pair of bearing bars have a height that is greater than the intervening swaged bars. This configuration allows the present grating system to extend across large gaps in a support structure than what was previously taught by other grating systems or assemblies.

CROSS REFERENCE TO RELATED APPLICATIONS

The present disclosure claims the benefit of U.S. Provisional Patent Application Ser. No. 63/253,809, filed on Oct. 8, 2021, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to grates and grating systems. More particularly, in one example, the present disclosure relates to a grating assembly which may accommodate vehicle traffic and pedestrian traffic. Specifically, in another example, the present disclosure relates to a grating system which may accommodate heavier wheel loads and/or longer clear spans, while maintaining a reasonable bearing bar depth and weight per square foot. This specific example, may have pairs of bearing bars and a space between pairs of bearing bars that improves manufacturability by maintaining space for ease of access to fabricate the assembly, while accommodating heavy loads at longer clear spans. Additionally, this grating system can provide for an ADA compliant bar spacing and may in other instances provide a closer bar spacing for a high-heel friendly walking surface.

BACKGROUND

Grating assemblies configured for supporting vehicle and/or pedestrian traffic are commonly used on sidewalks and road surfaces requiring venting and/or drainage therethrough. Often these grating systems are configured to permit various sizing of wheels and/or foot traffic to pass there over without catching or presenting a hazard thereto. Typically, as such grating assemblies are installed in areas where they are easily seen and not easily concealed, they are typically designed to be functional while also being aesthetically pleasing.

One such grating assembly is shown and described in U.S. Pat. No. 8,122,674, which is commonly owned and incorporated herein by reference. The grating system disclosed therein is commonly employed on a sidewalk and in areas of high volume pedestrian traffic. Given this area of use on sidewalks, the gap in the support structure that this assembly extends across is often only a few feet wide.

Another such grating assembly is shown and described in U.S. patent application Ser. No. 17/358,145, which is commonly owned and incorporated herein by reference. The grating system disclosed therein is advantageous for accommodating a higher volume of heavy use, such as found with roadway vehicular applications. This can also apply to other areas subject to heavy wheel loads, such as, manufacturing areas, alley ways or sidewalks. However, this particularly grating system extends across gaps in a support structure of only about 96 inches.

SUMMARY

There are scenarios where a grating assembly is needed in a support structure but the gap needed to covered by the grating assembly is larger than 96 inches. The present disclosure addresses these and other issues by providing a grating system incorporating a plurality paired bearing bars and intervening swaged bars to allow the grating assembly to extend across a larger gap in a support structure than which was previously possible. For example, the configuration detailed herein can now extend across gaps of 96 inches or more.

In one aspect, an exemplary embodiment of the present disclosure may provide a grating assembly comprising: a frame defined by a pair of end plates and a pair of side plates; a first pair of bearing bars extending transversely across the frame; a second pair of bearing bars extending transversely across the frame, wherein the second pair of bearing bars are spaced from the first pair of bearing bars; a plurality of swaged bars disposed between the first pair of bearing bars and the second pair of bearing bars; wherein the first pair of bearing bars has a height dimension that is greater than a height dimension of the swaged bars. This exemplary embodiment or another exemplary embodiment may further provide a first bearing bar from the first pair of bearing bars; a second bearing bar from the second pair of bearing bars; wherein the first bearing bar is spaced apart immediately adjacent the second bearing bar. This exemplary embodiment or another exemplary embodiment may further provide a first side surface and a second side surface on the first bearing bar from the first pair of bearing bars; a first side surface and a second side surface on the second bearing bar from the first pair of bearing bars; wherein the first side surface of the first bearing bar faces the second side surface of the second bearing bar, and there are no swaged bars between the first side surface of the first bearing bar and the second side surface of the second bearing bar. This exemplary embodiment or another exemplary embodiment may further provide wherein the plurality of swaged bars disposed between the first pair of bearing bars and the second pair of bearing bars includes: five swaged bars disposed between the first pair of bearing bars and the second pair of bearing bars. This exemplary embodiment or another exemplary embodiment may further provide a slot defined in each of the first bearing bar and the second bear bar; a cross member extending through the slot in each of the first bearing bar and the second bear bar; a weld that joins the second side surface of the first bearing bar to the cross member; a weld that joins the first side surface of the second bearing bar to the cross member; and wherein there is no weld in the space between the first and second bearing bars. This exemplary embodiment or another exemplary embodiment may further provide the height dimension of the first pair of bearing bars is in a range from three inches to twelve inches, and in one particular embodiment is in a range from three inches to nine inches; and the height dimension of the swaged bars is in a range from ¾ inch to 1.5 inches. This exemplary embodiment or another exemplary embodiment may further provide wherein the height dimension of the first pair of bearing bars is nine inches and height dimension of the swaged bars is one inch. This exemplary embodiment or another exemplary embodiment may further provide a space defined between the first side surface of the first bearing bar and the second side surface of the second bearing bar; wherein the space between the first and second bearing bars extends laterally relative to the frame between the end plates. This exemplary embodiment or another exemplary embodiment may further provide a width of the space between the first and second bearing bars is in range from about ¼ inch to about ½ inch. This exemplary embodiment or another exemplary embodiment may further provide a clear span dimension of the frame greater than 96 inches. This exemplary embodiment or another exemplary embodiment may further provide wherein the clear span dimension of the frame is at least 120 inches, and can be at least 149 inches.

In another aspect, an embodiment of the present disclosure may provide a grating assembly comprising: a frame defined by a pair of end plates and a pair of side plates; a first plurality of bearing bars extending transversely across the frame, wherein the first plurality of bearing bars includes a first bearing bar and a second bearing bar, wherein the first bearing bar is spaced apart immediately adjacent the second bearing bar; and a first side surface and a second side surface on the first bearing bar, and a first side surface and a second side surface on the second bearing bar, wherein the first side surface of the first bearing bar faces the second side surface of the second bearing bar; a second plurality of bearing bars extending transversely across the frame, wherein the second plurality of bearing bars is spaced from the first plurality of bearing bars; a plurality of swaged bars disposed between the first plurality of bearing bars and the second plurality of bearing bars, and wherein there are no swaged bars between the first side surface of the first bearing bar and the second side surface of the second bearing bar; wherein the first plurality of bearing bars has a height dimension that is greater than a height dimension of the swaged bars. This exemplary embodiment or another exemplary embodiment may further provide a clear span dimension of the frame greater than 96 inches.

In yet another aspect, an exemplary embodiment may include A method of assembly a grating assembly comprising: constructing a frame adapted to carry a grate and be installed in a support structure; extending a first plurality of bearing bars transversely across the frame, wherein the first plurality of bearing bars includes a first bearing bar and a second bearing bar; spacing the first bearing bar apart from and immediately adjacent a second bearing bar, wherein a first side surface of the first bearing bar faces a second side surface of the second bearing bar; extending a second plurality of bearing bars transversely across the frame, wherein the second plurality of bearing bars is spaced from the first plurality of bearing bars; and extending a plurality of swaged bars between the first plurality of bearing bars and the second plurality of bearing bars. This exemplary embodiment or another exemplary embodiment may include extending the frame over a clear span dimension greater than 136 inches. This exemplary embodiment or another exemplary embodiment may include ensuring that there are no swaged bars between the first side surface of the first bearing bar and the second side surface of the second bearing bar. This exemplary embodiment or another exemplary embodiment may include disposing five swaged bars between the first plurality of bearing bars and the second plurality of bearing bars. This exemplary embodiment or another exemplary embodiment may include sliding a cross member through a slot in the first bearing bar; and welding the cross member to the first bearing bar on only one side of the first bearing bar. This exemplary embodiment or another exemplary embodiment may include sliding the cross member through a slot in the second bearing bar; and welding the cross member to the second bearing bar on only one side of the second bearing bar. This exemplary embodiment or another exemplary embodiment may include ensuring there is no weld in a space defined between the first and second bearing bars.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Sample embodiments of the present disclosure are set forth in the following description, are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims.

FIG. 1 is a top isometric view of a grating system according to one aspect of the present disclosure.

FIG. 2 is a top isometric exploded view of a grating system having at least one pair of adjacent bearing bars according to one aspect of the present disclosure.

FIG. 3 is a side elevation view of a cross member of a grating system according to one aspect of the present disclosure.

FIG. 4 is a side elevation view of a swaged bar of a grating system according to one aspect of the present disclosure.

FIG. 5 is a side elevation view of a support plate or bearing bar of a grating system according to one aspect of the present disclosure.

FIG. 6A is a cross sectional operational view of one exemplary step for fabricating a grating system according to one aspect of the present disclosure.

FIG. 6B is a cross sectional operational view of another exemplary step for fabricating a grating system according to one aspect of the present disclosure.

FIG. 7 is a top view of the grating system according to one aspect of the present disclosure.

FIG. 8 is a cross section view of the grating system taken along line 8-8 in FIG. 7 .

FIG. 9A is a cross section view of the grating system taken along line 9A-9A in FIG. 8 .

FIG. 9B is a cross section view of the grating system taken along line 9B-9B in FIG. 8 .

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

With reference to FIGS. 1 and 2 , a grating assembly of the present disclosure is shown and generally indicated as grating assembly 10 (which may also be referred to herein as grating assembly 10). Grating assembly 10 is contemplated to be installed on or within a supporting structure 12 and may further include a pair of end plates 14 and a pair of side plates 15 fixedly connected to define a rigid frame 17, at least one support plate or bearing bar 16, at least one cross member 18, a plurality of swaged bars or swaged bars 22, and at least one lock rod or lock bar 24. The at least one bearing bar 16 may include one or more pairs of bearing bars that are spaced apart immediately adjacent the other bearing of the bar. The spaced apart pair of bearing bars may be separated from other pairs of spaced apart bearing bars and a plurality of swaged bars 22 are positioned therebetween. In one exemplary embodiment there may be five swaged bars 22 disposed between each pair of bearing bars 16. The configuration of having two immediately adjacent and slightly spaced apart bearing bars separated by five swaged bars 22 may enable grating assembly 10 to extend across larger gaps within the supporting structure than what was previously capable for supporting heavy equipment thereon. Frame 17 has a total span dimension 23 defined as the total distance between the outer surfaces of end plates 14. Frame 17 has a clear span dimension 21 defined as the unsupported distance between end plates 14. Clear span dimension 21 is greater than 96 inches. In one particular example, the configuration of assembly 10 enables the clear span dimension 21 to be at least 120 inches. Thus, the configuration of assembly 10 enables assembly 10 to extend across larger gaps in support structure 12 than what was previously capable.

Supporting structure 12, as shown and discussed herein, is contemplated as a substantially planar structure such as a concrete sidewalk, roadway or the like. It will be understood; however, that supporting structure 12 may include any suitable structure and/or support system such as metal beams or the like, as may be found in bridges, elevated walkways, platforms or similar applications. Further it will be understood that grating assembly 10 may be sized and/or configured for installation in supporting structures 12 of varying materials and/or having varying profiles as dictated by the desired implementation. Accordingly, as described herein, use in relation to a sidewalk and/or roadway will be understood as an exemplary use and installation of grating assembly 10 and not a limiting example thereof. Supporting structure 12 is contemplated to have a surface, for example, a walking surface of a sidewalk or a road surface, that is substantially planar and coincides with a plane defined by the top of grating assembly 10, as discussed herein, to maintain a generally even and flat transition between supporting structure 12 and grating assembly 10. This may facilitate installation without having portions of grating assembly 10 extending above or below the surface of supporting structure 12 to eliminate potential hazards or dangers to users, user vehicles, and/or to grating assembly 10 and supporting structure 12.

End plates 14 may have a first side 26 opposite a second side 28 and defining the thickness of end plates 14 therebetween. End plates 14 may have a first end 30 spaced apart from a second end 32. The maximum dimension of the end plates extends between first end 30 and second end 32. With respect to the frame 17, the dimension or length of the end plate extending between first end 30 and second end 32 defines a longitudinal direction therebetween. A top edge 34 spaced apart from a bottom edge 36 and defining a vertical direction therebetween. End plates 14 may extend longitudinally relative to frame 17 in that they may be oriented perpendicular to bearing bars 16 and swaged bars 22 which extend in a lateral or transverse direction relative to frame 17 so as to extend across a gap or hole in the support structure 12 parallel with the clear span dimension 21. Accordingly, it will be understood that the longitudinal direction defined between first and second ends 30 and 32 of end plates 14 is relative to frame 17, bearing bars 16 and swaged bars 22, and is not a limiting orientation of assembly 10.

Side plates 15 may be size similarly to end plates and extend perpendicular thereto. Side plates 15 may be rigidly connected to the respective first and second ends 30, 32 of the end plates 14. The rigid connection of plates 15 to plates 14 defines an opening in frame 17. The bearing bars 16 and swaged bars 22 are disposed within the opening of frame 17 to define a grate that is configured to extend across a gap in the support surface 12 in the clear span dimension 21 to allow heavy objects to traverse over the top of the grating assembly 10. Side plates extend in a direction perpendicular to the clear span dimension 21. The maximum dimension of side plates is known as the width dimension 25 of assembly 10. Dimension 25 is perpendicular to clear span dimension 21 and perpendicular to total span dimension 23.

End plates 14 and side plates 15 may be generally planar and may be constructed out of any suitable material including steel, stainless steel, or the like. Although depicted here and discussed herein as generally rectangular, end plates 14 and side plates 15 (and grating assembly 10) may have any suitable profile and/or shape as dictated by the installation parameters, as discussed further below.

Bearing bars 16 may be defined as longitudinal in that they may extend parallel to swaged bars 22 and perpendicularly to end plates 14 but are not to be understood as a limiting factor in the orientation of grating assembly 10. Bearing bars 16 may then have a first side 38 separated from a second side 40 and defining the thickness of bearing bars 16 therebetween. The thickness of the bearing bars 16 is oriented in the same direction as the maximum dimension or length of the end plates 14, and the thickness of the bearing bars 16 is oriented perpendicular to the length or maximum dimension of the side plates 15. In one embodiment, the thickness of bearing bars is 3/16 inch. Bearing bars 16 may further include a first end 42 spaced apart from a second end 44 and a length or maximum dimension of the bearing bar 16 extends therebetween. A top edge 46 is spaced apart from a bottom edge 48 and defining the vertical direction between. Bearing bars 16 may further include at least one vertical through-opening, or slot, 50 defined therein for receiving cross members 18 therethrough, as discussed further below. Slots 50 may have a top edge oriented towards the top edge 46 of bearing bar 16 and may further define the uppermost limit of slots 50. Slots 50 may further have a bottom edge oriented towards the bottom edge 48 of bearing bars 16 and may further define the lowermost limit slots 50. Bearing bars 16 may further include one or more apertures 52 operable to receive lock rod(s) or bar(s) 24 therein, as discussed further below.

Bearing bars 16 may be generally planar and may be constructed of any suitable material including steel or other suitable metals, as dictated by the desired implementation.

As depicted in FIG. 2 , the bearing bars 16 may include a first pair of bearing bars. The pair of bearing bars 16 may include a first bearing bar 16A and a second bearing bar 16B. The pair of bearing bars 16 defined by the first bearing bar 16A and the second bearing bar 16B are immediately adjacent each other. However, due to the nature of the grating assembly 10, there is a space between the pair of bearing bars. The space between the pair of bearing bars is defined between the surface of the first side 38 of the first bearing bar 16A and the surface of the second side of the second bearing bar 16B. The space between the first and second bearing bars 16A, 16B extends laterally relative to the frame 17 between the end plates 14. The width of the space defined between the first and second bearing bars 16A, 16B extends in the longitudinal direction of the frame, or a direction parallel to the length of end plates 14. The maximum dimension (i.e., the lateral dimension of the gap relative to the frame) of the space between the first and second bearing bars 16A, 16B is commensurate with the length of the bearing bars that extend laterally or transversely across the opening of the frame, which is otherwise approximately equal to clear span dimension 21 of frame 17. The width dimension of the space between the first and second bearing bars 16A, 16B may be selected by designer of the assembly 10 to meet application specific needs. In one particular embodiment, it has been found that the width of the space between the first and second bearing bars 16A, 16B may be from ¼ inch to about ½ inch.

Swaged bars 22 may have a first side 82 spaced apart from a second side 84 defining the thickness thereof, a first end 86 spaced longitudinally apart from a second end 88, and a top edge 90 spaced vertically apart from a bottom edge 92. In one embodiment, the thickness of the swaged bars 22 is 3/16 inch. Swaged bars 22 may further include one or more apertures 94, which may align with apertures 52 in bearing bars 16 to accept one or more lock rods or bars 24 therein, as discussed further herein. As previously mentioned herein, swaged bars 22 may be defined as lateral in that they may extend perpendicularly from end plates 14 but the lateral orientation of swaged bars 22 is not to be understood as a limitation as to the orientation of grating assembly 10 but instead as a position relative to the other components thereof.

As depicted in FIG. 2 , the swaged bars 22 may include one or more sets of pluralities of swaged bars 22. State otherwise, groups of swaged bars 22 are organized between respective pairs of bearing bars 16. In one embodiment, one group or one set of swaged bars is composed of five swaged bars, namely, a first swaged bar 22A, a second swaged bar 22B, a third swaged bar 22C, a fourth swaged bar 22D, and a fifth swaged bar 22E. Within the set of swaged bars 22, each respective swaged bar 22 is spaced from an adjacent one. The outermost swaged bars from the set would be spaced apart and disposed adjacent respective bearing bars 16 that bound each side of the set of swaged bars 22. For example, the first swaged bar 22A is disposed adjacent the second bearing bar 16B from a first pair of bearing bars, and the fifth swaged bar 22E is disposed adjacent the first bearing bar from a second pair of bearing bars. The spaces between the swaged bars 22 may be similar in size and configuration as the space between first and second bearing bars 16A, 16B. However, other configurations of the space between the swaged bars 22 is possible. Further, an alternative numbers of swaged bars 22 to form the set is entirely possible depending on the application specific needs and requirements for supporting a heavy load and extending across a larger gap in the support surface 12 in the direction of the clear span dimension.

As with the other components discussed herein, swaged bars 22 may be generally planar and may similarly be constructed of any suitable material including metal such as steel, or the like, as dictated by the desired implementation.

Cross members 18 may have a first side 54 spaced apart from a second side 56 defining the thickness thereof. Cross members 18 may further include a first end 58 spaced apart from a second end 60 and defining a transverse direction therebetween, and a top edge 62 spaced vertically apart from a bottom edge 64. As with end plates 14, cross members 18 may be defined as lateral in that they extend perpendicularly to bearing bars 16 and swaged bars 22. Cross members are generally rigid and configure to extend through slots 50 in the bearing bars 16. The cross members 18 are oriented such that their maximum dimension is oriented parallel to the end plates 14 and the thickness dimension of the cross members is parallel to the side plates 15. As with the other components discussed herein, cross members 18 may be generally planar and may be similarly constructed of any suitable material including steel or other suitable metals, as dictated by the desired implementation.

Lock bars 24 may be generally cylindrical bars or rods having a first end 96 spaced laterally apart from a second end 98. According to one aspect, lock bars 24 may be hollow with first and second ends 96, 98 being open ends thereof. According to another aspect, lock bars may be hollow with first and second ends 96, 98 closed and/or capped at the ends of lock bars 24. According to yet another aspect, lock bars 24 may be solid or substantially solid. Lock bars 24 may be formed of any suitable material and be compressible, as discussed further below.

With reference to FIGS. 3-6 , the sizing and relationship of the individual components of grating assembly 10 will now be discussed in more detail.

The slots 50, apertures 52, and apertures 94 may be sized according to the relative sizes of cross members 18, and lock bars 24, as discussed further below. As it relates to other relative sizing, some components of grating assembly 10, may best be understood with reference to the relative dimensions of the components and the relationships therebetween. In particular, the overall width and length of grating assembly 10 may be defined by the specific installation parameters and may vary accordingly. For example, where the grating assembly 10 is employed on a sidewalk or on the side of a roadway, which are both an exemplary type of support structure 12, assembly 10 may be configured as a general square with the width and length being relatively equal. In other installations, grating assembly 10 may be rectangular in which the plates 14 are longer than the plates 15 such that the bearing bars 16 and swaged bars 22 extend transversely or laterally in the direction of the shorter dimension to extend across the gap in the support structure 12 in the direction of the clear span dimension 21. Alternatively, frame 17 may accommodate any suitable shape or dimension, as necessary. Accordingly, the references to the dimensions of grating assembly 10 components will be understood to be relative to facilitate assembly thereof and to further provide of proper interaction between components. For example, where a component is indicated to have a specific height relative to another component, the physical measurement of that height is not limited but instead the individual components are understood to maintain the relative height comparisons, regardless of physical size.

Accordingly, with reference to FIG. 3 , cross members 18 may have an overall first height H1. The first height H1 may be defined as the vertical height from top 62 to bottom edge 64 of cross members 18. In one exemplary embodiment, the cross member may be in a range from ¾ inch to 1½ inch. In one particular embodiment, the first height H1 is about 1.125 inch.

With reference to FIG. 4 , swaged bars 22 may have an overall second height H2 defined from the top edge 90 to the bottom edge 92 thereof. Swaged bars 22 may also include a partial height H3, which may represent the distance between the top edge 90 and a center point in apertures 94 defined through swaged bars 22. H3 is approximately half that of height H2. In one embodiment, height H2 is in a range from about ¾ to about 1.25 inch. In one particular example, height H2 is about one inch.

With reference to FIG. 5 , bearing bars 16, or more particularly, slots 50 of bearing bars 16 may have a fourth height H4 defined from the top edge to the bottom edge of slots 50. Bearing bars 16 may further include a fifth height H5 defined from the top edge of slots 50 to the top edge 46 of bearing bar 16 and an sixth height H6 defined from the top edge 34 of bearing bars 16 to a center line of apertures 52 defined through bearing bars 16. Bearing bar may include an overall seventh height H7 defined from the top edge 48 of bearing bar 16 to the bottom edge 48 of bearing bar. In one embodiment, the overall seventh height H7 is in a range from about three inches to about twelve inches, but would more likely bee from three inches to nine inches. In one particular example, the overall seventh height H7 is about nine inches.

In one particular example, each of the bearing bars 16 from the pair of immediately adjacent but spaced apart bearing bars may have the same height H7. However, it is possible that they have differing heights H7 without departing from the scope of the present disclosure. For example, the first bearing bar 16A can have a height H7 that greater than or less than the height H7 of the second bearing bar 16B.

In another example, it is possible for a pair of bearing bars 16 to have the same height H7 but have a different height H7 from a different pair of bearing bars 16. Recall, each pair of bearing bars 16 is spaced from another pair of bearing bars with swaged bars 22 positioned therebetween. Thus, both bearing bars 16A, 16B from the first pair of bearing bars 16 could have a height H7 that is equal to about nine inches, and a second pair of bearing bars could have a different height H7 without departing from the scope of the present disclosure.

Slot 50 has a first width W1. First width W1 is in a range from about 0.0625 inch to about 0.3125 inch. In one particular example, first width W1 is about 0.1875 inch or about 3/16 inch. The slots 50 may be spaced apart from other spots by a distance W2. The distance W2 between adjacent slots may be in a range from about two inches to about six inches. In one particular example, the distance W2 is about four inches. The distance W2 between successive slots 50 is contemplated as being uniform along the length of bearing bar 16. As such, slots 50 are spaced at regular intervals, such as four inch intervals. However, the intervals between the slots 50 may be non-uniform to accommodate application specific or installation specific needs of the of the grating assembly 10.

Each of these heights H1 through H7 may determine relative relationships between specific components of grating assembly 10, which will now be discussed. Specifically, height H4 of slots 50 may be slightly larger than overall height H1 of cross members 18 to facilitate slidable engagement therewith.

Height H2 and height H5 may be substantially identical such that top edge 90 of swaged bars 22, top edge 34 of end plates 14, and top edge 46 of bearing bars 16 may all be substantially planar when grating assembly 10 is fully assembled. Similarly, height H3 and height H6 may be substantially identical to properly align a center point of apertures 52 and apertures 94 for insertion of lock bars or rods 24 therethrough, as discussed below.

Having thus described the elements and components of grating assembly 10, the assembly and configuration thereof will now be discussed.

With reference to FIG. 2 and FIGS. 6A-9B, and as mentioned previously herein, grating assembly 10 may be sized according to the desired implementation and may have an indiscriminant length and width. Specifically, end plates 14 may have any length between first end 30 and second end 32 as dictated by the desired implementation. Same with the side plates 15. Similarly bearing bars 16, cross members 18, and swaged bars 22 may have any length between the ends thereof. Grating assembly 10 may further have any varying number of immediately adjacent pairs of bearing bars 16, cross members 18, swaged bars 22, and/or lock bars 24, as desired and/or necessary based on the specific size and installation parameters for a particular implementation thereof. According to one example, as shown in the figures, there may be approximately five swaged bars 22 between each pair of immediately adjacent bearing bars 16. Therefore, in an example with thirteen pairs of bearing bars 16 (for a total of twenty six bearing bars 16), there sixty-five swaged bars 22. Similarly the cross members 18, cross member lock bars 20, and lock bars 24 may vary in number depending upon the longitudinal length of grating assembly 10.

As described with the example above, and in most installations, grating assembly 10 is contemplated to have two end plates 14 with at least one bearing bar 16 at either lateral end thereof, which may be joined with side plate 15 or may be omitted so that only side plate 15 exists. Grating assembly 10 may have any shape, as discussed herein; however, grating assembly 10 is contemplated to most commonly be configured to form a generally square or rectangular shape. Accordingly, and solely for purposes of clarity and simplicity in this disclosure, grating assembly 10 will be discussed as a square configuration having two end plates 14 and a series of paired bearing bars 16 evenly spaced and disposed therein with swaged bars 22 disposed between the pairs of bearing bars 16. Further, grating assembly 10 will be described with a plurality of cross members 18 and lock bars or rods 24.

Thus, two end plates 14 may first be arranged with a first side plate 15 placed at the first end 30 of end plates 14 and a second side plate 15 placed at the second end 32 of end plates 14. These first and second side plates 15 may be fixed to end plates 14 through any suitable means, including, but not limited to, welding the first and second ends of side plates 15 to the sides (either first side 26 or second side 28, depending on placement) of end plates 14. Any additional bearing bars may be evenly spaced between the side plates 15 and attached to end plates 14 to form a general framework of grating assembly 10, if desired. This collectively forms frame 17. The frame can be assembled to ensure that the clear span dimension 21 is greater than 96 inches as the configuration used herein allows the assembly 10 to extend across greater dimensions of previous grating assemblies or grates that use only single bearing bars spaced with intervening swaged bars.

Once the frame 17 has been assembled, the bearing bars 16 and swaged bars 22 may be coupled to the frame 17. The bearing bars 16 and the swaged bars 22 define a grate on the top surface thereof. In the exemplary installation shown in FIG. 6A, frame 17 is placed in a stationary position and then, the bearing bars 16 and the swaged bars 22 are coupled to the frame by moving or lowering them down the frame 17 as shown by Arrow A. However, this is merely exemplary and not intended to be limiting. For example, this process could be performed in another manner. Such as, first placing the bearing bars 16 and the swaged bars 22 in an upside-down stationary position, and then lowering or moving the frame 17 downward on the bearing bars 16 and swaged bars 22. The bearing bars 16 and swaged bars 22 are fixedly attached, such as through welding, to the frame 17.

Next, for each slot 50 defined in the bearing bars 16, a cross member may first be slidably inserted therein, as best seen in FIG. 6B, until the first and second ends 58, 60 thereof align with the first and second bearing bars 16. Cross members 18 may be inserted into slots 50 from either direction, but will be described as being inserted right to left, as indicated by the arrows B in FIG. 6B.

With reference to FIG. 8 and FIG. 9B, once cross members 18 are fully inserted in slots 50, each instance where cross members 18 encounter a bearing bar 16, the cross members 18 are welded (or otherwise fixedly connected) to bearing bars 16. One example of these welds is best seen in FIG. 8 at reference 110. According to this example, welds 110 may be full or partial perimeter welds that substantially surround the sides 54 and 56 cross members 18. While it is possible for welds to be on both sides 38 and 40 of the bearing bars 16, one particular embodiment shown in FIG. 8 and FIG. 9B does not utilize this configuration. Specifically, one exemplary advantage of using the pair of bearing bars 16 being immediately adjacent each other relative to the swaged bars 22 is that it is possible for a configuration that only utilizes a weld 110 on one side of each bearing bar 16. That is to say, a first weld 110 may be on the second side 40 of first bearing bar 16A to join cross member 18 with first bearing bar 16A, and a second weld 110 may be on the first side 38 of second bearing bar 16B to join cross member 18 with second bearing bar 16B. It has been envisioned that this unique configuration permits ease of manufacture advantages while maintaining structure rigidity for the assembly 10. Since this welding process can use only one-sided welds, the assembly may also ensure that there are no welds in the space between the first and second bearing bars 16A, 16B.

With reference to FIG. 6B and FIG. 9A, swaged bars 22 are supported by cross members 18 and are positioned above the cross members. With swaged bars 22 positioned above cross members 18, the lock bars or rods 24 are inserted through apertures 52 and 94 as shown by Arrow B. The lock bars or rods 24 may be compressed between each swaged bar 22 (as indicated by the arrow C in FIG. 7 ), further forming a series of compressed sections 112. These compressed sections 112 may cause lock bars or rod 24 to narrow in thickness as viewed from above (FIG. 7 ) while simultaneously causing them to expand in height as viewed from the side (FIG. 9B) to lock the lock bars 24 in position within apertures 52, 94 while simultaneously securing swaged bar 22 in relative configuration to maintain the desired spacing between swaged bars 22 and to prevent lateral movement thereof during use. Thus, the relationship between swaged bars, along with bearing bars 16 are locked into the final configuration where assembly 10 may then be installed into a supporting structure 12. Further, the configuration of assembly 10 may facilitate an overall size of the assembly 10 to extend across a larger gap in support structure 12 in the direction of the clear span dimension 21 than what was previously possible, while at the same time promoting a longer lifespan and more durable use of grating assembly 10, even when exposed to heavy and repeated traffic, including vehicle traffic.

According to one aspect, each component of grating assembly 10 may be welded or otherwise affixed together through any suitable means, including, but not limited to mechanical fasteners, epoxies, or the like. One notable exception may be to exclude mechanical connections such as welds or mechanical fasteners on the top edges 34, 46, and 90 of the end plates 14, bearing bars 16 and swaged bars 22 to prevent any physical structure extending above the physical plane established by these edges when grating assembly 10 is fully assembled. This may prevent damage to grating assembly 10 during use. For example, a mechanical fastener extending above this plane may present a tripping hazard, or where used with vehicles, a tire damage hazard, or a catch point for snow plows or the like.

The grating assembly 10, as described herein, may provide distinct advantages in that it may be installed and used in areas needing to extend across a larger gap in the support structure 12 all while supporting heavy traffic, including heavy weight vehicles, while maintaining its structural form with an increased lifespan. Particularly, due to the strength of the materials for the given size, a previous grating assembly could only extend across a gap in support structure of about 96 inches. However, utilizing the configuration herein with the immediately adjacent pair of bearing bars 16 that are spaced from other pairs by a series of swaged bars 22 having the dimensions and welding configurations detailed herein now enables the assembly 10 to extend across a gap in support structure of 120 inches in the direction of the clear span dimension 21. The clear span dimension 21 is parallel to the length of the bearing bars, and perpendicular to the longitudinal direction of the frame.

Additionally, while the term pair has been used herein with reference to the bearing bars 16, other embodiments can include two or more bearing bars with no swaged bars 22 therebetween. Thus, an embodiment of the present disclosure can employ a first plurality of bearing bars 16 extending transversely across the frame, wherein the first plurality of bearing bars includes a first bearing bar 16A and a second bearing bar 16B (and there could be more, such as three, four, five or more bearing bars, or there may just be two), wherein the first bearing bar 16A is spaced apart immediately adjacent the second bearing bar 16B; and a first side surface 38 and a second side surface 40 on the first bearing bar 16A, and a first side surface 38 and a second side surface 40 on the second bearing bar 16B, wherein the first side surface 38 of the first bearing bar 16A faces the second side surface 40 of the second bearing bar 16B.

Various inventive concepts may be embodied as one or more methods, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. Specifically, although the assembly of grating assembly 10 is described herein with a particular sequence, it will be understood that the elements and components of grating assembly 10 may be assembled in any suitable order. According to one non-limiting example, the swaged bars 22 and lock bars 24 may be assembled with bearing bars 16 and the lock bars 24 may be compressed prior to assembling the remaining components.

While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

The articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” The phrase “and/or,” as used herein in the specification and in the claims (if at all), should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and/or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law.

As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

When a feature or element is herein referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “connected”, “attached” or “coupled” to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. It will also be appreciated by those of skill in the art that references to a structure or feature that is disposed “adjacent” another feature may have portions that overlap or underlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper”, “above”, “behind”, “in front of”, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”, “lateral”, “transverse”, “longitudinal”, and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

Although the terms “first” and “second” may be used herein to describe various features/elements, these features/elements should not be limited by these terms, unless the context indicates otherwise. These terms may be used to distinguish one feature/element from another feature/element. Thus, a first feature/element discussed herein could be termed a second feature/element, and similarly, a second feature/element discussed herein could be termed a first feature/element without departing from the teachings of the present invention.

An embodiment is an implementation or example of the present disclosure. Reference in the specification to “an embodiment,” “one embodiment,” “some embodiments,” “one particular embodiment,” “an exemplary embodiment,” or “other embodiments,” or the like, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the invention. The various appearances “an embodiment,” “one embodiment,” “some embodiments,” “one particular embodiment,” “an exemplary embodiment,” or “other embodiments,” or the like, are not necessarily all referring to the same embodiments.

If this specification states a component, feature, structure, or characteristic “may”, “might”, or “could” be included, that particular component, feature, structure, or characteristic is not required to be included. If the specification or claim refers to “a” or “an” element, that does not mean there is only one of the element. If the specification or claims refer to “an additional” element, that does not preclude there being more than one of the additional element.

As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word “about” or “approximately,” even if the term does not expressly appear. The phrase “about” or “approximately” may be used when describing magnitude and/or position to indicate that the value and/or position described is within a reasonable expected range of values and/or positions. For example, a numeric value may have a value that is +/−0.1% of the stated value (or range of values), +/−1% of the stated value (or range of values), +/−2% of the stated value (or range of values), +/−5% of the stated value (or range of values), +/−10% of the stated value (or range of values), etc. Any numerical range recited herein is intended to include all sub-ranges subsumed therein.

Additionally, the method of performing the present disclosure may occur in a sequence different than those described herein. Accordingly, no sequence of the method should be read as a limitation unless explicitly stated. It is recognizable that performing some of the steps of the method in a different order could achieve a similar result.

In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.

Moreover, the description and illustration of various embodiments of the disclosure are examples and the disclosure is not limited to the exact details shown or described. 

1. A grating assembly comprising: a frame defined by a pair of end plates and a pair of side plates; a first pair of bearing bars extending transversely across the frame; a second pair of bearing bars extending transversely across the frame, wherein the second pair of bearing bars is spaced from the first pair of bearing bars; a plurality of swaged bars disposed between the first pair of bearing bars and the second pair of bearing bars; wherein the first pair of bearing bars has a height dimension that is greater than a height dimension of the plurality of swaged bars.
 2. The grating assembly of claim 1, further comprising: a first bearing bar from the first pair of bearing bars; a second bearing bar from the second pair of bearing bars; wherein the first bearing bar is spaced apart immediately adjacent the second bearing bar.
 3. The grating assembly of claim 2, further comprising: a first side surface and a second side surface on the first bearing bar from the first pair of bearing bars; a first side surface and a second side surface on the second bearing bar from the first pair of bearing bars; and wherein the first side surface of the first bearing bar faces the second side surface of the second bearing bar, and there are no swaged bars between the first side surface of the first bearing bar and the second side surface of the second bearing bar.
 4. The grating assembly of claim 3, wherein the plurality of swaged bars disposed between the first pair of bearing bars and the second pair of bearing bars includes: five swaged bars disposed between the first pair of bearing bars and the second pair of bearing bars.
 5. The grating assembly of claim 3, further comprising: a slot defined in each of the first bearing bar and the second bear bar; a cross member extending through the slot in each of the first bearing bar and the second bear bar; a weld that joins the second side surface of the first bearing bar to the cross member; a weld that joins the first side surface of the second bearing bar to the cross member; and wherein there is no weld in a space defined between the first and second bearing bars.
 6. The grating assembly of claim 3, further comprising: a space defined between the first side surface of the first bearing bar and the second side surface of the second bearing bar; wherein the space between the first and second bearing bars extends laterally relative to the frame between the end plates.
 7. The grating assembly of claim 8, further comprising: a width of the space between the first and second bearing bars is in range from about ¼ inch to about ½ inch.
 8. The grating assembly of claim 1, further comprising: the height dimension of the first pair of bearing bars is in a range from three inches to nine inches; and the height dimension of the swaged bars is in a range from ¾ inch to 1.5 inches.
 9. The grating assembly of claim 6, wherein the height dimension of the first pair of bearing bars is nine inches and height dimension of the swaged bars is one inch.
 10. The grating assembly of claim 1, further comprising: a clear span dimension of the frame greater than 96 inches.
 11. The grating assembly of claim 10, wherein the clear span dimension of the frame is at least 120 inches.
 12. A method of assembly for a grating assembly comprising: constructing a frame adapted to carry a grate and be installed in a support structure; extending a first plurality of bearing bars transversely across the frame, wherein the first plurality of bearing bars includes a first bearing bar and a second bearing bar immediately adjacent each other; spacing the first bearing bar apart from and immediately adjacent the second bearing bar, wherein a first side surface of the first bearing bar faces a second side surface of the second bearing bar; extending a second plurality of bearing bars transversely across the frame, wherein the second plurality of bearing bars is spaced from the first plurality of bearing bars; and extending a plurality of swaged bars between the first plurality of bearing bars and the second plurality of bearing bars.
 13. The method of claim 12, further comprising: extending the frame over a clear span dimension greater than 96 inches.
 14. The method of claim 12, further comprising: ensuring that there are no swaged bars between a first side surface of the first bearing bar and a second side surface of the second bearing bar.
 15. The method of claim 14, further comprising: disposing five swaged bars between the first plurality of bearing bars and the second plurality of bearing bars.
 16. The method of claim 12, further comprising: sliding a cross member through a slot in the first bearing bar; and welding the cross member to the first bearing bar on only one side of the first bearing bar.
 17. The method of claim 16, further comprising: sliding the cross member through a slot in the second bearing bar; and welding the cross member to the second bearing bar on only one side of the second bearing bar.
 18. The method of claim 17, further comprising: ensuring there is no weld in a space defined between the first and second bearing bars.
 19. A grating assembly comprising: a frame defined by a pair of end plates and a pair of side plates; a first plurality of bearing bars extending transversely across the frame, wherein the first plurality of bearing bars includes a first bearing bar and a second bearing bar, wherein the first bearing bar is spaced apart immediately adjacent the second bearing bar; and a first side surface and a second side surface on the first bearing bar, and a first side surface and a second side surface on the second bearing bar, wherein the first side surface of the first bearing bar faces the second side surface of the second bearing bar; a second plurality of bearing bars extending transversely across the frame, wherein the second plurality of bearing bars is spaced from the first plurality of bearing bars; a plurality of swaged bars disposed between the first plurality of bearing bars and the second plurality of bearing bars, and wherein there are no swaged bars between the first side surface of the first bearing bar and the second side surface of the second bearing bar; wherein the first plurality of bearing bars has a height dimension that is greater than a height dimension of the plurality of swaged bars.
 20. The grating assembly of claim 19, further comprising: a clear span dimension of the frame greater than 96 inches. 